EP2371529A2

EP2371529A2 - Improved composite materials

Info

Publication number: EP2371529A2
Application number: EP20110155080
Authority: EP
Inventors: Martin Simmons; John Cawse; George Green
Original assignee: Hexcel Composites Ltd
Current assignee: Hexcel Composites Ltd
Priority date: 2006-11-06
Filing date: 2007-11-06
Publication date: 2011-10-05
Anticipated expiration: 2027-11-06
Also published as: EP2540491A2; JP6339148B2; EP2371530A3; JP5606986B2; CN103144385B; WO2008056123A1; US8980771B2; ES2952708T3; US8263503B2; US8980770B2; EP2540491B1; JP6027643B2; EP2371529B1; EP2371531A2; JP2015007245A; ES2959472T3; JP2017071778A; US20080295955A1; EP2371529A3; US9603229B2

Abstract

A composite material, the composite material comprising at least one prepreg, said prepreg comprising at least one polymeric resin and at least one fibrous reinforcement; and conducting particles dispersed in the polymeric resin.

Description

The present invention relates to composite materials, and particularly, but not exclusively, to fibre reinforced composite materials.
Composite materials are increasingly used in structural applications in many fields owing to their attractive mechanical properties and low weight in comparison to metals. Composites are known in the field to consist of layering of materials to provide a structurally advantageous laminate type material. However, whilst electrical conductivity is one of the most obvious attributes of metals, composite materials based on fibre reinforcements (such as adhesive films, surfacing films, and pre-impregnated (prepreg) materials), generally have much lower electrical conductivity.
Conventional composite materials usually consist of a reinforcement phase, generally comprising continuous or discontinuous fibres, and a matrix phase, generally a thermoset or thermoplastic polymer. Most early first generation matrix polymers for the manufacture of composites were, by nature, brittle and it has therefore been necessary to develop more toughened versions. The composites materials used as primary structures in aerospace applications tend to be so-called second or third generation toughened materials.
There is a particular need for composite materials which exhibit electrical conductivity for several applications. These applications include use for protection against lightning strikes, electrostatic dissipation (ESD), and electromagnetic interference (EMI). Prior composite materials, such as those based upon carbon fibres, are known to have some degree of electrical conductivity which is usually associated with the graphitic nature of the carbon filaments. However the level of electrical conductivity provided is insufficient for protecting the composite material from the damaging effects of, for example, a lightning strike.
Second generation toughened composites represent an improvement over earlier first generation materials due to incorporation of toughening phases within the matrix material. This includes incorporation of metals in to the assembly via expanded foils, metal meshes, or interwoven wires. Typical metals which are used for this purpose include aluminium, bronze and copper. These composite materials can provide better electrical conductivity. However, they are generally heavy and have significantly degraded mechanical and aesthetic properties. These composites are usually found at the first one or two plies of the material, and therefore a poor overall surface finish often results.
In the event of a lightning strike on second generation composites, damage is normally restricted to the surface protective layer. The energy of the lightning strike is typically sufficient to vaporise some of the metal and to bum a small hole in the mesh. Damage to the underlying composite may be minimal, being restricted to the top one or two plies. Nevertheless, after such a strike it would be necessary to cut out the damaged area and make good with fresh metal protection and, if required, fresh composite.
As already mentioned, materials with carbon fibres do possess some electrical conductivity. However, the conductivity pathway is only in the direction of the fibres, with limited ability for dissipation of electrical current in directions orthogonal to the plane of the fibre reinforcement (z direction). Carbon reinforced materials often comprise an interleaf structure which results in inherently low conductivity in the z direction due to the electrical insulation properties of the interleaf. The result of such an arrangement can lead to disastrous effects when damaged by lightning as the electrical discharge can enter the interleaf, volatilise the resin therein, and cause mass delamination and penetration through the composite material.
So-called third generation toughened composite materials are based on interleaf technology where resinous layers are alternated with fibre reinforced plies, and provide protection against impacts. However, these resin layers act as an electrical insulator and therefore electrical conductivity in the z direction of the material is poor (i.e. orthogonal to the direction of the fibres). Lightning strikes on the composite material can result in catastrophic failure of the component, with a hole being punched through a multiple ply laminate.
The present invention therefore seeks to provide a composite material which has improved electrical conductivity properties in comparison to prior attempts as described herein, and has little or no additional weight compared to a standard composite material. The present invention also seeks to provide composite materials which have the improved electrical conductivity without detriment to the mechanical performance of the material. The present invention further seeks to provide a method of making the composite material having improved electrical conductivity properties.
A further aim is to provide a lightning strike tolerant composite material which is convenient to manufacture, use, and repair.
According to a first aspect of the present invention there is provided a composite material comprising;

i) at least one prepreg, said prepreg comprising at least one polymeric resin and at least one fibrous reinforcement; and
ii) conductive particles dispersed in the polymeric resin.

According to a second aspect of the present invention there is provided a method of making a composite material comprising the steps of;

i) providing at least one prepreg, said prepreg comprising at least one polymeric resin and at least one fibrous reinforcement; and
ii) dispersing conductive particles the polymeric resin.

According to a third aspect of the present invention there is provided the use of conductive particles for reducing an initial bulk resistivity of a constituent polymeric resin of a composite material, the composite material comprising a prepreg, said prepreg comprising said polymeric resin and at least one fibrous material, wherein the conductive particles are dispersed in the polymeric resin.
Surprisingly, it has been found that use of conducting particles in a polymeric resin of a prepreg provide reduced bulk resistivity, thereby improving z directional electrical conductivity through the composite material. Additionally, it has been found that the conducting particles dispersed in the resin formulation, and subsequently prepregged, result in a prepreg having substantially similar handling characteristics in comparison with an equivalent unmodified prepreg.
It is understood that references to a composite material include materials which comprise a fibre reinforcement, where the polymeric resin is in contact with the fibre but not impregnated in the fibre. The term composite material also includes an alternative arrangement in which the resin is partially embedded or partially impregnated in the fibre, commonly known in the art as prepreg. The prepreg may also have a fully impregnated fibrous reinforcement layer. The composite material may also include multilayered materials which have multiple fibre-rein-fibre layers.
It is understood that references to "interleaf structure" refers to the multi-layered material having a fibre-resin-fibre structure. The term "interleaf" refers to the polymeric resin which is present, and interleaved, between the fibre layers. References to "interleaf thickness" are to the average distance across the interleaf layer as measured from the uppermost surface of a lower fibre ply to a lowermost surface of an upper fibre ply. The interleaf thickness is therefore equivalent to the thickness of the interleaved polymeric resin layer, and references to interleaf thickness and polymeric resin thickness are interchangeable.
The terms interlayer, interleaf resin layer, and fibre free layer as used herein are all interchangeable, and refer to the polymeric resin layer.
The term polymeric resin as used herein refers to a polymeric system.
The term "polymeric resin" and "polymeric system" are used interchangeably in the present application, and are understood to refer to mixtures of chain lengths of resins having varying chain lengths. The term polymeric therefore includes an embodiment where the resins present are in the form of a resin mixture comprising resins having chain length greater than 3. The resulting polymeric resin when cured forms a crosslinked matrix of resin.
Bulk resistivity refers to the measurement of the "bulk" or "volume" resistivity of a semi-conductive material. It can be seen that reference to an "initial bulk resistivity" relates to the bulk resistivity of a polymeric resin prior to addition of conducting particles. The value in Ohms-m is the inherent resistance of a given material. Ohms-m (Ωm) is used for measuring the conductivity of a three dimensional material. The bulk electrical resistivity p of a material is usually defined by the following: $ρ = \frac{RA}{l}$

where;

p is the static resistivity (measured in ohm metres),
R is the electrical resistance of a uniform specimen of the material (measured in ohms),
l is the length of the specimen (measured in metres)
A is the cross-sectional area of the specimen (measured in square metres)

In the present invention, the volume resistivity is only measured in the z-direction (through the composite material thickness). In every case it is referenced as the "volume" resistivity as the thickness is always taken into consideration in the calculation.
The aim of the invention is achieved by incorporating into the interleaf region of the prepreg a low volume fraction of conducting particles at a level in itself wholly insufficient to impart electrical conductivity to the polymeric resin from which the prepreg is made.
Furthermore, it has been found that addition of conducting particles, such as carbon particles or silver coated glass spheres, to the composite material reduces bulk resistivity and therefore provides electrical conductance levels which exceed those that might have been reasonably expected.
A further benefit of the invention is an improved thermal conductivity for the prepreg, leading to faster heat up times and better dissipation of the heat generated during the cure exotherm. A still further benefit is that the electrical resistance of the composite material is essentially unchanged with variation in temperature.
The reduction in bulk resistivity and improvement in conductivity results in improved lightning strike performance. This improvement achieved by the present invention is therefore surprising in view of the low levels of electrically conductive particles employed, and the high electrical resistivity normally exhibited by the interleaf resin itself.
It is envisaged that the terms "resistivity" and "conductivity" used herein refer to electrical resistivity and electrical conductivity respectively.
As used herein, the term "particles" refers to discrete three dimensional shaped additives which are distinct, treated as an individual units, and separable from other individual additives, but this does not preclude additives from being in contact with one another. The term embraces the shapes and sizes of electrically conductive particles described and defined herein.
The term "aspect ratio" used herein is understood to refer to the ratio of the longest dimension to the shortest dimension of a three dimensional body. The term is applicable to additives of any shape and size as used herein. Where the term is used in relation to spherical or substantially spherical bodies, the relevant ratio would be that of the largest cross sectional diameter with the smallest cross sectional diameter of the spherical body. It will therefore be understood that a perfect sphere would have an aspect ration of 1:1. The aspect ratios as specified herein for electrically conductive particles are based on the dimensions of the particles after any metal coating has been applied.
References to the size of the electrically conductive particles are to the largest cross sectional diameter of the particles.
Suitable electrically conductive particles may include, by way of example, spheres, microspheres, dendrites, beads, powders, any other suitable three-dimensional additives, or any combination thereof.
The conductive particles used in the present invention may comprise any suitable conducting particles. It will be understood that this would include any suitable conductive particles capable of reducing bulk resistivity and thereby facilitating electrical conductivity of the composite material.
The electrically conductive particles may be selected from metal coated conducting particles, non-metallic conducting particles, or a combination thereof.
The conductive particles are dispersed in the polymeric resin. It is envisaged that the term "dispersed" may include where the conductive particles are present substantially throughout the polymeric resin without being present in a substantially higher concentration in any part of the polymeric resin. Additionally, the term "dispersed" also includes the conductive particles being present in localised areas of polymeric resin if reduced bulk resistivity is only required in specific areas of the composite material.
The metal coated conducting particles may comprise core particles which are substantially covered by a suitable metal.
The core particles may be any suitable particles. Suitable particles, by way of example, include those formed from polymer, rubber, ceramic, glass, mineral, or refractory products such as fly ash.
The polymer may be any suitable polymer which is a thermoplastic or thermosetting polymer. The terms 'thermoplastic polymer' and 'thermosetting polymer' are as characterised herein.
The core particles formed from glass may be any of the types used for making solid or glass microspheres.
Examples of suitable silica containing glass particles include soda glass, borosilicate, and quartz. Alternatively, the glass may be substantially silica free. Suitable silica free glasses include, by way of example, chalcogenide glasses.
The core particles may be porous or hollow or may themselves be a core-shell structure, for example core-shell polymer particles. The core particles may be first coated with an activating layer, adhesion promoting layer, primer layer, semiconducting layer or other layer prior to being metal coated.
The core particles are preferably hollow particles formed from glass. Use of hollow core particles formed from glass may be advantageous in applications where weight reduction is of particular importance.
Mixtures of the core particles may be used to obtain, for example, lower densities or other useful properties, for instance a proportion of hollow metal coated glass particles may be used with a proportion of metal coated rubber particles to obtain a toughened layer with a lower specific gravity.
Metals suitable for coating the core particles include, by way of example, silver, gold, nickel, copper, tin, aluminium, platinum, palladium, and any other metals known to possess high electrical conductivity.
Multiple layers of metal coatings may be used to coat the core particles, for example gold coated copper, or silver coated copper. Simultaneous deposition of metals is also possible, thereby producing mixed metal coatings.
The metal coating may be carried out by any of the means known for coating particles. Examples of suitable coating processes include chemical vapour deposition, sputtering, electroplating, or electroless deposition.
The metal may be present as bulk metal, porous metal, columnar, microcrystalline, fibrillar, dendritic, or any of the forms known in metal coating. The metal coating may be smooth, or may comprise surface irregularities such as fibrils, or bumps so as to increase the specific surface area and improve interfacial bonding.
The metal coating may be subsequently treated with any of the agents known in the art for improving interfacial bonding with the polymeric resin, for example silanes, titanates, and zirconates.
The electrical resistivity of the metal coating should be preferably less than 3 x 10^-5 Ωm, more preferably less than 1 x 10^-7 Ωm, and most preferably less than 3 x 10^-8 Ωm.
The metal coated conducting particles may be of any suitable shape for example spherical, ellipsoidal, spheroidal, discoidal, dendritic, rods, discs, acicular, cuboid or polyhedral. Finely chopped or milled fibres may also be used, such as metal coated milled glass fibres. The particles may have well defined geometries or may be irregular in shape.
The metal coated conducting particles should possess an aspect ratio of <100, preferably <10, and most preferably <2.
The metal coated conducting particle size distribution may be monodisperse or polydisperse. Preferably, at least 90 % of the metal coated particles have a size within the range 0.3 µm to 100 µm, more preferably 1 µm to 50 µm, and most preferably between 5 µm and 40 µm.
The electrically conductive particles may be non-metallic conducting particles. It will be understood that this would include any suitable non-metallic particles not having a metal coating, and capable of reducing bulk resistivity and thereby facilitating electrical conductivity of the composite material.
Suitable non-metallic conducting particles include, by way of example, graphite flakes, graphite powders, graphite particles, graphene sheets, fullerenes, carbon black, intrinsically conducting polymers (ICPs - including polypyrrole, polythiophene, and polyaniline), charge transfer complexes, or any combination thereof.
An example of a suitable combination of non-metallic conducting particles includes combinations of ICPs with carbon black and graphite particles.
The non-metallic conducting particle size distribution may be monodisperse or polydisperse. Preferably, at least 90 % of the non-metallic conducting particles have a size be within the range 0.3 µm to 100 µm, more preferably 1 µm to 50 µm, and most preferably between 5 µm and 40 µm.
The electrically conductive particles have a size whereby at least 50% of the particles present in the polymeric resin have a size within 10 µm of the thickness of the polymeric resin layer. In other words the difference between the thickness of the resin layer and the size of the electrically conductive articles is less than 10 µm. Preferably the electrically conductive particles have a size whereby at least 50% of the particles present in the polymeric resin have a size within 5 µm of the thickness of the polymeric resin layer.
The size of at least 50% of the electrically conductive particles is therefore such that they bridge across the interleaf thickness (polymeric resin layer), and the particles are in contact with an upper fibrous reinforcement ply and a lower fibrous reinforcement ply arranged about the polymeric resin layer.
The electrically conductive particles may be present in the range 0.2 vol.% to 20 vol.% of the composite material. More preferably, the conducting particles are present in the range 0.4 vol.% to 15 vol.%. Most preferably, the conducting particles are present in the range 0.8 vol.% to 10 vol.%.
In an alternative embodiment, the electrically conductive particles may be present in an amount of less than 10 vol.% of the polymeric resin layer.
It can be seen that the preferred ranges of the electrically conductive particles are expressed in vol.% as the weight of the particles may exhibit a large variation due to variation in densities.
The electrically conductive particles may be used alone or in any suitable combination.
Without wishing to be unduly bound by theory, it has been found that the benefits of the invention may be conferred due to the conductive particles (either metal coated or non-metallic) acting as electrical conductance bridges across the interleaf thickness (i.e. across the polymeric resin layer and between the layers of fibrous reinforcement), thereby connecting plies of fibrous reinforcement and improving the z directional electrical conductance.
It has also been found that use of electrically conductive particles with size substantially equal to the interleaf thickness advantageously allows for electrical conductance across the composite material (in the z plane) to be provided at relatively low loading levels. These low loading levels of electrically conductive particles are less than would be typically required to make the polymeric resin itself electrically conducting.
The electrically conductive particles therefore facilitate electrical conductivity by lowering the bulk resistivity of the composite material.
The composite material may also comprise carbon nano materials. The carbon nano materials may be selected from carbon nanotubes, and carbon nanofibres. The carbon nano materials may be any suitable carbon nanotubes or carbon nanofibres.
The carbon nano materials may have a diameter in the range 10-500nm. Preferred carbon nano materials may have a diameter in the range 100 to 150nm.
The carbon nanomaterials may preferably have a length in the range 1-10 µm.
The carbon nano materials may provide additional electrically conducting pathways across the composite material (in the z plane) by further bridging across the interleaf. The fibrous reinforcements are arranged in the form of layers or plies comprising a number of fibre strands. The composite material comprises at least two fibrous reinforcement plies which are arranged either side of a polymeric resin layer. As well as providing electrical conductivity in the x and y planes of the material, the plies act as supporting layers to the structure of the material, and substantially contain the polymeric resin.
The fibrous reinforcement of the prepreg may be selected from hybrid or mixed fibre systems which comprise synthetic or natural fibres, or a combination thereof. The fibrous reinforcement is electrically conductive, and therefore is formed from fibres which are electrically conductive.
The fibrous reinforcement may preferably be selected from any suitable material such as metallised glass, carbon, graphite, metallised polymer fibres (with continuous or discontinuous metal layers), the polymer of which may be soluble or insoluble in the polymeric resin. Any combination of these fibres may be selected. Mixtures of these fibres with non-conducting fibres (such as fibreglass for example) may also be used.
The fibrous reinforcement is most preferably formed substantially from carbon fibres.
The fibrous reinforcement may comprise cracked (i.e. stretch-broken) or selectively discontinuous fibres, or continuous fibres. It is envisaged that use of cracked or selectively discontinuous fibres may facilitate lay-up of the cured composite material prior to being fully cured according to the invention, and improve its capability of being shaped.
The fibrous reinforcement may be in the form of woven, non-crimped, non-woven, unidirectional, or multiaxial textile tapes or tows.
The woven form is preferably selected from a plain, satin, or twill weave style. The non-crimped and multiaxial forms may have a number of plies and fibre orientations.
Such styles and forms of fibrous reinforcement are well known in the composite reinforcement field, and are commercially available from a number of companies including Hexcel Reinforcements of Villeurbanne, France.
The polymeric resin of the prepreg preferably comprises at least one thermoset or thermoplastic resin.
The term 'thermoset resin' includes any suitable material which is plastic and usually liquid, powder, or malleable prior to curing and designed to be moulded in to a final form. The thermoset resin may be any suitable thermoset resin. Once cured, a thermoset resin is not suitable for melting and remoulding. Suitable thermoset resin materials for the present invention include, but are not limited to, resins of phenol formaldehyde, urea-formaldehyde, 1,3,5-triazine-2,4,6-triamine (Melamine), bismaleimide, epoxy resins, vinyl ester resins, benzoxazine resins, phenolic resins, polyesters, unsaturated polyesters, cyanate ester resins, or any combination thereof. The thermoset resin is preferably selected from epoxide resins, cyanate ester resins, bismaleimide, vinyl ester, benzoxazine, and phenolic resins.
The term 'thermoplastic resin' includes any suitable material which is plastic or deformable, melts to a liquid when heated and freezes to a brittle, and forms a glassy state when cooled sufficiently. Once formed and cured, a thermoplastic resin is suitable for melting and re-moulding. Suitable thermoplastic polymers for use with the present invention include any of the following either alone or in combination: polyether sulphone (PES), polyether ethersulphone (PEES), polyphenyl sulphone, polysulphone, polyester, polymerisable macrocycles (e.g. cyclic butylene terephthalate), liquid crystal polymers, polyimide, polyetherimide, aramid, polyamide, polyester, polyketone, polyetheretherketone (PEEK), polyurethane, polyurea, polyarylether, polyarylsulphides, polycarbonates, polyphenylene oxide (PPO) and modified PPO, or any combination thereof.
The polymeric epoxy resin preferably comprises at least one of bisphenol-A (BPA) diglycidyl ether and bisphenol-F (BPF) diglycidyl ether and derivatives thereof; tetraglycidyl derivative of 4,4'-diaminodiphenylmethane (TGDDM); triglycidyl derivative of aminophenols, and other glycidyl ethers and glycidyl amines well known in the art.
The polymeric resin is applied to the fibrous reinforcement. The fibrous reinforcement may be fully or partially impregnated by the polymeric resin. In an alternative embodiment, the polymeric resin may be a separate layer which is proximal to, and in contact with, the fibrous reinforcement, but does not substantially impregnate said fibrous reinforcement.
The composite material may include at least one curing agent. The curing agent may be substantially present in the polymeric resin. It is envisaged that the term "substantially present" means at least 90 wt.% of the curing agent, preferably 95 wt.% of the curing agent.
For epoxy resins, the curing agents of the invention are those which facilitate the curing of the epoxy-functional compounds of the invention, and, particularly, facilitate the ring opening polymerisation of such epoxy compounds. In a particularly preferred embodiment, such curing agents include those compounds which polymerise with the epoxy-functional compound or compounds, in the ring opening polymerisation thereof.
Two or more such curing agents may be used in combination.
Suitable curing agents include anhydrides, particularly polycarboxylic anhydrides, such as nadic anhydride (NA), methylnadic anhydride, phthalic anhydride, tetrahydrophthalic anhydride, hexahydrophthalic anhydride, methyltetrahydrophthalic anhydride, methylhexahydrophthalic anhydride, endomethylenetetrahydrophthalic anhydride, or trimellitic anhydride.
Further suitable curing agents are the amines, including aromatic amines, e.g. 1,3-diaminobenzene, 1,4-diaminobenzene, 4,4'-diaminodiphenylmethane, and the polyaminosulphones, such as 4,4'-diaminodiphenyl sulphone (4,4'-DDS), and 3,3'-diaminodiphenyl sulphone (3,3'-DDS).
Also, suitable curing agents may include phenol-formaldehyde resins, such as the phenol-formaldehyde resin having an average molecular weight of about 550-650, the p-t-butylphenol-formaldehyde resin having an average molecular weight of about 600-700, and the p-n-octylphenol-formaldehyde resin, having an average molecular weight of about 1200-1400.
Yet further suitable resins containing phenolic groups can be used, such as resorcinol based resins, and resins formed by cationic polymerisation, such as dicyclopentadiene - phenol copolymers. Still additional suitable resins are melamine-formaldehyde resins, and urea-formaldehyde resins.
Different commercially available compositions may be used as curing agents in the present invention. One such composition is AH-154, a dicyandiamide type formulation, available from Ajinomoto USA Inc. Others which are suitable include Ancamide 1284, which is a mixture of 4,4'-methylenedianiline and 1,3-benzenediamine; these formulations are available from Pacific Anchor Chemical, Performance Chemical Division, Air Products and Chemicals, Inc., Allentown, USA.
The curing agent (s) is selected such that it provides curing of the resin component of the composite material when combined therewith at suitable temperatures. The amount of curing agent required to provide adequate curing of the resin component will vary depending upon a number of factors including the type of resin being cured, the desired curing temperature, and the curing time. Curing agents typically include cyanoguanidine, aromatic and aliphatic amines, acid anhydrides, Lewis Acids, substituted ureas, imidazoles and hydrazines. The particular amount of curing agent required for each particular situation may be determined by well-established routine experimentation.
Exemplary preferred curing agents include 4,4'-diaminodiphenyl sulphone (4,4'-DDS) and 3,3'-diaminodiphenyl sulphone (3,3'-DDS).
The curing agent, if present, may be present in the range 45 wt.% to 2 wt.% of the composite material. More preferably, the curing agent may be present in the range 30 wt.% to 5 wt.%. Most preferably, the curing agent may be present in the range 25 wt.% to 5 wt.%.
Accelerators, if present, are typically urones. Suitable accelerators, which may be used alone or in combination include N,N-dimethyl, N'-3,4-dichlorphenyl urea (Diuron), N'-3-chlorophenyl urea (Monuron), and preferably N,N-(4-methyl-m-phenylene bis[N',N'-dimethylurea] (TDI urone).
The composite material may also include additional ingredients such as performance enhancing or modifying agents. The performance enhancing or modifying agents, by way of example, may be selected from flexibilisers, toughening agents/particles, additional accelerators, core shell rubbers, flame retardants, wetting agents, pigments/dyes, flame retardants, plasticisers, UV absorbers, anti-fungal compounds, fillers, viscosity modifiers/flow control agents, tackifiers, stabilisers, and inhibitors.
Toughening agents/particles may include, by way of example, any of the following either alone or in combination: polyamides, copolyamides, polyimides, aramids, polyketones, polyetheretherketones, polyarylene ethers, polyesters, polyurethanes, polysulphones, high performance hydrocarbon polymers, liquid crystal polymers, PTFE, elastomers, and segmented elastomers.
Toughening agents/particles, if present, may be present in the range 45 wt.% to 0 wt.% of the composite material. More preferably, they may be present in the range 25 wt.% to 5 wt.%. Most preferably, they may be present in the range 15 wt.% to 10 wt.%.
A suitable toughening agent/particle, by way of example, is Sumikaexcel 5003P, which is commercially available from Sumitomo Chemicals of Tokyo, Japan. Alternatives to 5003P are Solvay polysulphone 105P, and Solvay 104P which are commercially available from Solvay of Brussels, Belgium.
Suitable fillers may include, by way of example, any of the following either alone or in combination: silicas, aluminas, titania, glass, calcium carbonate, and calcium oxide.
The composite material may comprise an additional polymeric resin which is at least one thermoset or thermoplastic resins as defined previously.
Whilst it is desirable that the majority of electrically conductive particles are located within the polymeric resin of the composite material, it is not generally detrimental if a small percentage of such particles are distributed within the fibrous reinforcement. The conducting particles may be suitably dispersed within the polymeric resin of the prepreg by conventional mixing or blending operations.
The mixed resin containing all the necessary additives and the conducting particles can be incorporated into prepreg by any of the known methods, for example a so-called lacquer process, resin film process, extrusion, spraying, printing or other known methods.
In a lacquer process all the resin components are dissolved or dispersed in a solvent and the fibrous reinforcement is dipped in the solvent, and the solvent is then removed by heat. In a resin film process the polymeric resin is cast as a continuous film, either from a lacquer or a hot melt resin, onto a substrate which has been treated with a release agent, and then the coated film is contacted against the fibrous reinforcement and, under the aid of heat and pressure, the resin film melts and flows into the fibres. A multiplicity of films may be used and one or both sides of the fibre layer may be impregnated in this way.
If the prepreg is made by a film or lacquer process, the majority of the conducting particles will be "filtered" by the reinforcing fibres and thus will be substantially prevented from entering the fibrous reinforcement because the particle size is larger than the distance between the reinforcing fibres. Other processes such as spraying or printing would enable the conducting particles to be placed directly onto the fibrous reinforcement with very low penetration of the said particles between the fibres. When metal coated hollow particles are used, it may be necessary to utilise lower shear mixing equipment to reduce the deforming effect that mixing may produce on the conducting particles.
The prepreg may be in the form of continuous tapes, towpregs, fabrics, webs, or chopped lengths of tapes, towpregs, fabrics, or webs. The prepreg may be an adhesive or surfacing film, and may additionally have embedded carriers in various forms both woven, knitted, and non-woven.
Prepregs formulated according to the present invention may be fabricated into final components using any of the known methods, for example manual lay-up, automated tape lay-up (ATL), automated fibre placement, vacuum bagging, autoclave cure, out of autoclave cure, fluid assisted processing, pressure assisted processes, matched mould processes, simple press cure, press-clave cure, or continuous band pressing.
The composite material may be in an embodiment comprising a single ply of conductive fibrous reinforcement, which has applied on one side a polymeric resin layer comprising electrically conductive particles. The composite material may be manufactured in a single ply embodiment and subsequently be formed in to multiple layers to provide an interleaf structure by lay-up. The interleaf structure is therefore formed during lay-up where a fibre-resin-fibre configuration arises.
The composite material may therefore comprise a single prepreg. Alternatively, the composite material may comprise a plurality of prepregs.
The polymeric resin layer thickness of the prepreg is preferably in the range 1 µm to 100 µm, more preferably 1 µm to 50 µm, and most preferably 5 µm to 50 µm.
Multiple layers of conductive composite materials may be used. Thus, by way of example, an assembly may be prepared using 12 plies of composite materials, and 4 plies of composite materials comprising conducting particles of the present invention, thus enhancing the conductivity of the final assembly. As a further example, a laminate assembly could be prepared from 12 plies of composite materials, and composite material comprising conducting particles and with no carbon fibre reinforcement. Optionally, where a composite material of the present invention is used, an electrically isolating layer can be placed between the carbon fibre plies and the resin surface. For example, a glass reinforced fibrous layer can be used as the isolating layer. It is understood that there are many possible assemblies that could be used, and those described herein are by way of example only.
A further benefit is that the composite material of the present invention, prior to being fully cured, is completely flexible and is suitable for automated tape lay up processes which are increasingly used in the manufacture of large composite structures in the aerospace industry.
The composite material of the invention may be fully or partially cured using any suitable temperature, pressure, and time conditions known in the art.
The composite material may be cured using a method selected from UV-visible radiation, microwave radiation, electron beam, gamma radiation, or other suitable thermal or non-thermal radiation.
Thus, according to a fourth aspect of the present invention there is provided a method of making a cured composite material comprising the steps of the second aspect, and subsequently curing the composite material.
The curing step of the fourth aspect may be using any known method. Particularly preferred are curing methods as described herein.
Thus according to a fifth aspect of the present invention there is provided a cured composite material which comprises a composite material according to the first aspect of the present invention, wherein the composite material is cured.
Whilst most of the following discussion concentrates on lightning strike protection, it will readily be seen that there are many potential applications for a composite material exhibiting reduced bulk resistivity and highly electrically conductivity. Thus, the level of conductivity achieved by the present invention will make the resulting composite materials suitable for use in electromagnetic shielding, electrostatic protection, current return, and other applications where enhanced electrical conductivity is necessary.
Furthermore, although much of the discussion centres around aerospace components, it is also possible to apply the present invention to lightning strike and other electrical management problems in wind turbines, buildings, marine craft, trains, automobiles and other areas of concern.
It is envisaged that the present invention, when used for aerospace components, can be used for primary structure applications (i.e. those parts of the structure which are critical for maintaining the integrity of the airplane), as well as secondary structure applications.
Thus, according to a sixth aspect of the present invention there is provided a process for making an aerospace article formed from a cured composite material comprising the steps of:

making a cured composite material in accordance with the method of the fourth aspect
using the cured composite material to produce an aerospace article by a known method.

Thus, according to a seventh aspect of the present invention there is provided an aerospace article comprising the cured composite material of the fifth aspect.
All of the features described herein may be combined with any of the above aspects, in any combination.
In order that the present invention may be more readily understood, reference will now be made, by way of example, to the following description and accompanying drawings, in which;

Figure 1: is a photograph of an upper surface of a damaged panel after a simulated lightning strike;
Figure 2: is a photograph of a lower surface of the damaged panel of Figure 1 after a simulated lightning strike;
Figure 3: is an ultrasonic C-scan of the damaged panel of Figures 1 and 2;
Figure 4: is a photograph of an upper surface of a damaged panel of the present invention after a simulated lightning strike;
Figure 5: is a photograph of a lower surface of the damaged panel of Figure 4 of the present invention after a simulated lightning strike;
Figure 6: is an ultrasonic C-scan of the damaged panel of Figures 4 and 5;
Figure 7: is a micrograph of a polished cross-section of the panel of Figures 4 and 5;
Figure 8: is a photograph of an upper surface of a damaged panel of the present invention after a simulated lightning strike;
Figure 9: is a photograph of a lower surface of the damaged panel of Figure 8 of the present invention after a simulated lightning strike; and
Figures 10: is an ultrasonic C-scan of the damaged panel of Figures 8 and 9.

In the following examples, "neat resin" refers to the basic polymeric matrix resin, in the absence of reinforcing fibres, used for manufacturing prepreg.
HexPly® M21 is an interleaved epoxy resin prepreg material available from Hexcel Composites, Duxford, Cambridge, United Kingdom.
LY1556 is an epoxy resin available from Huntsman Advanced Materials, Duxford, Cambridge, United Kingdom.
It will be understood that all tests and physical properties listed have been determined at atmospheric pressure and room temperature (i.e. 20°C), unless otherwise stated herein, or unless otherwise stated in the referenced test methods and procedures.

Comparative Example 1 (neat resin)

A neat epoxy resin sample of M21 was produced by blending all the components uniformly and curing in a thermostatically controlled oven at 180°C for 2 hours. As the sample of Example 1 did not comprise any conductive particles, it does not fall within the scope of the present invention, and is listed for comparative purposes. Surface resistivity was then measured for the cured resin plaque using a model 272 resistivity meter from Monroe Electronics by placing a circular electrode on the surface of the neat resin specimen a reading the measured and displayed value on the instrument panel. It is important that contact between the specimen and probe is good, and therefore neat resin samples should be flat, smooth and uniform. Results are shown in Table 1

Example 2

Samples of resin (M21) comprising silver coated solid glass spheres (size 20µm) present at the following levels:

2-1 1.0 vol.% (equivalent to 2.5 wt.%)

2-2 2.0 vol.% (equivalent to 5.0 wt.%)

2-3 3.0 vol.% (equivalent to 7.5 wt.%)

2-4 4.0 vol.% (equivalent to 10.0 wt.%)

were prepared and cured in an oven at 180°C for 2 hours. Surface resistivity was then measured using the same resistivity meter and procedure as detailed in Example l. Results are shown in Table 1.

Example 3

Samples of resin (M21) comprising silver coated polymethylmethacrylate (PMMA) particles (size 20µm) present at the following levels:

3-1 2.5 vol.% (equivalent to 2.5 wt.%)

3-2 5.0 vol.% (equivalent to 5.0 wt.%)

3-3 7.5 vol.% (equivalent to 7.5 wt.%)

3-4 10.0 vol.% (equivalent to 10.0 wt.%)

were prepared and cured in an oven at 180°C for 2 hours. Surface resistivity was then measured using a resistivity meter and procedure as detailed in Example 1. Results are shown in Table 1.

Example 4

Samples of resin (M21) comprising silver coated hollow glass spheres (size 20µm) present at the following levels:

4-1 2.5 vol.% (equivalent to 2.5 wt.%)

4-2 5.0 vol.% (equivalent to 5.0 wt.%)

4-3 7.5 vol.% (equivalent to 7.5 wt.%)

4-4 10.0 vol.% (equivalent to 10.0 wt.%)

were prepared and cured in an oven at 180°C for 2 hours. Surface resistivity was then measured using a resistivity meter and procedure as detailed in Example 1. Results are shown in Table 1.

The surface resistivity is a measure of resistivity of thin films having uniform thickness. Surface resistivity is measured in ohms/square (Ω/sq.), and it is equivalent to resistivity for two-dimensional systems. The term is therefore a measure of resistivity for a current passing along the surface, rather than through the material which is expressed as bulk resistivity. Surface resistivity is also referred to as sheet resistance.

Table 1: Surface resistivity of M21 resin modified with conductive particles.

Example	Conductive additive	Loading (vol.%)	Loading (wt. %)	Surface Resistivity (Ω/square)
1	No additive	0	0	2.0 x 10¹²
2-1	Silver coated solid glass spheres	1.0	2.5	3.4 x 10¹²
2-2	Silver coated solid glass spheres	2.0	5.0	3.0 x 10¹²
2-3	Silver coated solid glass spheres	3.0	7.5	2.5 x 10¹²
2-4	Silver coated solid glass spheres	4.0	10.0	2.6 x 10¹²
3-1	Silver coated PMMA particles	2.5	2.5	2.4 x 10¹²
3-2	Silver coated PMMA particles	5.0	5.0	3.0 x 10¹²
3-3	Silver coated PMMA particles	7.5	7.5	1.8 x 10¹²
3-4	Silver coated PMMA particles	10.0	10.0	1.7 x 10¹²
4-1	Silver coated hollow glass spheres	2.5	2.5	2.7 x 10¹²
4-2	Silver coated hollow glass spheres	5.0	5.0	2.8 x 10¹²
4-3	Silver coated hollow glass spheres	7.5	7.5	1.8 x 10¹²
4-4	Silver coated hollow glass spheres	10.0	10.0	1.9 x 10¹²

These results demonstrate that addition of conductive silver particles at 10 vol. % or lower has an effect on the surface resistivity of cured neat epoxy resins, and generally improves conductivity of the composite material.

Example 5 (neat resin)

A neat epoxy resin sample was produced in which LY1556 (50.0g) was added carbon nanofibres (150 nm diameter) as produced by Electrovac of Austria. Using a Flaktec Speedmixer the fibres were dispersed in the resin at 2500rpm for 15 minutes. Silver coated beads (20 µm) at 2.0 vol.%, carbon nanofibres (110nm) at 2.0 wt.%, and 4,4'-diaminodiphenylsulphone were added to the mixture and blended by stirring. The formulation was cured in a thermostatically controlled oven at 180°C for 2 hours. Surface resistivity was then measured for the cured plaque using a model 272 resistivity meter from Monroe Electronics. Results are summarised in Table 2.

Table 2: Surface resistivity of composites comprising silver coated glass spheres and carbon nanofibres (CNF).

Example	110 nm CNFs (wt. %)	Silver solid glass spheres (vol. %)	Silver coated glass spheres (wt. %)	Surface Resistivity (Ω/square)
1	-	-	-	2 x 10¹²
2-2	-	2.0	5.0	3.0 x 10¹²
5	2	2.0	5.0	4.7 x 10²

These results show that the combination of carbon nanofibres with silver coated glass spheres further lowers the surface resistivity of the epoxy resin when compared to an epoxy resin that contains only the silver coated solid glass spheres.
In the following examples, "carbon composite" refers to the basic matrix resin, in the presence of reinforcing carbon fibres, used for manufacturing prepreg.

Example 6 (carbon composite)

M21 resin was produced by blending the components in a Z-blade mixer (Winkworth Machinery Ltd, Reading, England). The resin was coated as a thin film on silicone release paper which was then impregnated on intermediate modulus IM7 carbon fibre available from (Hexcel Composites, Duxford, UK) at a resin weight of 35 % using a hot press to make a unidirectional prepreg. A five ply prepreg was laid up unidirectionally which was approximately 10cm by 10cm and cured on a vacuum table at a pressure of 7 bar at 177°C for 2 hours. A z-direction electrical resistance value of the composite was determined first by gold sputtering a square on either side of a rectangular shaped sample in order to ensure low contact resistance. Resistivity was then measured by applying probes to the gold sputtered area of the specimens and using a power source (TTi EL302P Programmable 30V/2A Power Supply Unit, Thurlby Thandar Instruments, Cambridge, UK) that was capable of varying either voltage or current.

Example 7 (carbon composite)

M21 resin was modified with silver coated glass spheres (20 µm) at a range of 0.8-2.4 vol.% of the resin and the components were blended in a Winkworth mixer. The resin was coated as a thin film on silicone release paper and was then impregnated on intermediate modulus IM7 carbon fibre at a resin weight of 35 % using a hot press to make a unidirectional prepreg. A five ply prepreg of approximately 10cm by 10cm was laid up unidirectionally and cured on a vacuum table at a pressure of 7 bar at 177°C for 2 hours. A z-direction electrical resistance value was determined according to the method of Example 5. Results are summarised in Table 3. Table 3: Volume resistivity of carbon composite modified with silver coated glass spheres.

Example Silver coated glass spheres (vol.%) Silver coated glass spheres (wt.%) Z-direction volume resistivity (Ωm)

6 - - 3.66

7-1 0.8 2 2.13

7-2 1.6 4 1.89

7-3 2.4 6 1.75
The results in Table 3 clearly show a decrease in z-direction volume resistivity when compared to a neat resin material of Example 6, and also reducing resistivity when the amount of silver coated glass spheres are increased in the material.

Example 8 (carbon composite)

M21 resin was modified with silver coated hollow glass spheres (20 µm) at a range of 2.5-10.0 vol.% of the resin, and the components were blended in a Winkworth mixer. The resin was coated as a thin film on silicone release paper and was then impregnated on intermediate modulus IM7 carbon fibre at a resin weight of 35 % using a hot press to make a unidirectional prepreg. A five ply prepreg of approximately 10cm by 10cm was laid up unidirectionally and cured on a vacuum table at a pressure of 7 bar at 177°C for 2 hours. A z-direction electrical resistance value was determined according to the method of Example 6. Results are summarised in Table 4.

Table 4: Volume resistivity of carbon composite modified with silver coated hollow glass spheres according to Example 8.

Example	Silver coated hollow glass spheres (vol.%)	Silver coated hollow glass spheres (wt.%)	Z-direction volume resistivity (Ωm)
8-1	2.5	2.5	0.116
8-2	5.0	5.0	0.064
8-3	7.5	7.5	0.032
8-4	10.0	10.0	0.019

The results in Table 4 clearly show a decrease in z-direction volume resistivity with increases in the amount of silver coated glass spheres in the material.

Example 9 (carbon composite)

M21 resin was modified with silver coated polymethylmethacrylate particles (20 µm) at a range of 2.5-10.0 vol.% of the resin. The resin was produced by blending the components in a Winkworth mixer. The resin was coated as a thin film on silicone release paper and was then impregnated on intermediate modulus IM7 carbon fibre at a resin weight of 35 % using a hot press to make a unidirectional prepreg. A five ply prepreg of approximately 10cm by 10cm was laid up unidirectionally and cured on a vacuum table at a pressure of 7 bar at 177°C for 2 hours. A z-direction electrical resistance value was determined according to the method of Example 6. Results are summarised in Table 5.

Table 5: Volume resistivity of carbon composite modified with silver coated PMMA spheres.

Example	Silver coated PMMA particles (vol.%)	Silver coated PMMA particles (wt.%)	Z-direction volume resistivity (Ωm)
9-1	2.5	2.5	0.567
9-2	5.0	5.0	0.103
9-3	7.5	7.5	0.110
9-4	10.0	10.0	0.052

The results in Table 5 clearly show a decrease in z-direction volume resistivity with increases in the amount of silver coated glass spheres in the material.

Example 10 (carbon composite)

M21 resin was modified with dendritic silver/copper (40 µm) at a loading of 0.30 vol.% of the resin. The resin was produced by blending the components in a Winkworth mixer. The resin was coated as a thin film on silicone release paper and was then impregnated on intermediate modulus IM7 carbon fibre at a resin weight of 35 % using a hot press to make a unidirectional prepreg. A five ply prepreg of approximately 10cm by 10cm was laid up unidirectionally and cured on a vacuum table at a pressure of 7 bar at 177°C for 2 hours. A z-direction electrical resistance value was determined according to the method of Example 6. Results are summarised in Table 6.

Example 11 (carbon composite)

M21 resin was modified with silver coated glass beads (100 µm) at a loading of 1.0 vol.% of the resin. A prepreg and composite was produced according to example 9. Z-direction electrical resistance value was determined as per Example 6. Results are summarised in Table 6.

Example 12 (carbon composite)

M21 resin was modified with silver coated glass fibres (190 µm) at a loading of 1.25 wt.% of the resin. A prepreg and composite was produced according to example 9. Z-direction electrical resistance value was determined as per Example 6. Results are summarised in Table 6.

Table 6: Volume resistivity of carbon composite modified with different conducting particles.

Example	Conducting particle	Particles (vol.%)	Particles (wt. %)	Z-direction volume resistivity (Ωm)
10	Dendritic silver/copper (40µm)	0.30	2.5	12.26
11	Silver coated glass beads (100µm)	1.0	2.5	1.10
12	Silver coated glass fibres (190µm)	1.25	2.5	2.89

The results in Table 6 show a decrease in z-direction volume resistivity generally with increases in the amount of electrically conductive particles. Additionally, the results show a particularly good reduction in Example 11 where silver coated glass spheres are used which have a size substantially equal to the polymeric resin layer thickness.

Example 13 (carbon composite)

M21 prepreg was produced according to Example 12. A 6 ply quasi-isotropic (QI) laminate of approximate size 10cm x 10cm was prepared and cured on a vacuum table at a pressure of 7 bar at 177°C for 2 hours. The glass transition temperature, Tg, of the composite was determined by dynamic thermal analysis from the storage modulus trace, E', to be 194.5°C. A square sample was cut from the cured panel and the z-direction resistivity measured as follows. To ensure good electrical contact, the appropriate parts of the composite were vacuum coated with gold in the vicinity where connection was to be made with the power supply. The resistivity was then determined by applying a current of 1 amp from the power supply and measuring the resulting voltage. Table 7: Volume resistivity of the composite of Example 16.

Direction Lay up and size Z -direction Volume Resistivity (Ωm)

z QI (3.9cm x 3.9cm x 0..16cm) 19.70

Example 14 (carbon composite)

M21 resin was modified with 20 µm silver coated glass beads at (2 vol.%, 5 wt.%) and prepreg was produced according to the method of Example 13. A 6 ply quasi-isotropic laminate of approximate size 10cm x 10cm was prepared and cured on a vacuum table at a pressure of 7 bar at 177°C for 2 hours. The glass transition temperature (Tg) of the composite was determined as for Example 14 to be 196.0°C. Thus the addition of the silver coated beads does not have a deleterious effect on the Tg. A square sample was cut from the cured panel and the z-direction resistivity measured as for Example 13. Resistivity is significantly improved. Table 8: Volume resistivity of the composite of Example 14.

Direction Lay up and size Z -direction Volume Resistivity (Ωm)

z QI (3.8cm x 3.8cm x 0.16cm) 0.024

Example 15 (carbon composite)

M21 resin was modified with 20 µm silver coated glass beads at (2 vol.%, 5 wt.%) and carbon nanofibres (150 nm diameter) at 2 wt.% of the resin. Prepreg was produced according to Example 13. A 12 ply quasi-isotropic laminate of approximate size 10cm x 10cm was prepared and cured on a vacuum table at a pressure of 7 bar at 177°C for 2 hours. The glass transition temperature (Tg) of the composite was determined as for Example 14 to be 196.5°C. Thus the addition of the silver coated beads has not had a deleterious effect on the Tg. A square sample was cut from the cured panel and the z-direction resistivity measured as for Example 13. Resistivity is significantly improved. Table 9: Volume resistivity of the composite of Example 15.

Direction Lay up and size Z-direction Volume Resistivity (Ωm)

z QI (3.8cm x 3.8cm x 0.16cm) 0.023

Example 16 (Simulated Lightning Strike)

M21 resin was produced using a Winkworth mixer and then filmed onto silicone release paper. This resin film was then impregnated onto unidirectional intermediate modulus carbon fibre, using a pilot scale UD prepregger, which produced a prepreg with an areal weight of 268g/m² at 35 wt.% of resin. Two six-ply prepregs were produced (lay up 0/90) which were approximately 60cm by 60cm and these were cured on a vacuum table at a pressure of 7 bar at 177°C for 2 hours.
The panels were tested to Zone 1A; surfaces of the aeroplane for which there is a high probability of initial lightning flash attachment (entry or exit) with low probability of flash hang on, such as radomes and leading edges. Zone 1A also includes swept leaders attachment areas. The zone 1A test has three waveform components, high current component A (2x10⁶A, <500µs), intermediate current component B (average 2kA, <5ms) and continuing current component C (200C, <ls). Both surfaces of the panels were abraded around the edges to ensure a good connection to the outer frame. The electrode was connected to the panel via a thin copper wire. The copper wire provides a path for the current and vaporises on test. It is needed as the voltage generated is not enough to break down the air.
Figures 1 and 2 show a damaged panel of example 16 after simulated lightning strike. The panel 10, which does not comprise metal coated particles, showed severe damage on both upper surface 11 shown in Figure 1, and lower surface 12 shown in Figure 2.

An Ultrasonic c-scan 20 was also performed and is shown in Figure 3. The Ultrasonic C-scan 20 of the damaged panel 10 shown in Figures 1 and 2 was performed using an R/D Tech Omniscan MX from Olympus. The scan 20 shows that the damage area for an unmodified panel 10 is very large.

Table 10: Test parameters of lightning strike tests for Example 16.

Figure	A Component Current, I (kA)	Action Integral, AI (10⁶A²s)	B Component current, I (kA)	C Component Charge, Q
1	191.7	2.04	1.74	31.3
2	191.7	2.04	1.72	24.3

Table 11: Description of damaged area after lightning strike test

Figure	Description of Damage
1	■ Upper surface; delamination and dry fibres. Unusual scorch mark on surface. 330mm x 250mm
1	■ Bottom surface; delamination and dry fibres. 420mm x 230mm. Hole through panel.
2	■ Upper surface; delamination and dry fibres. 280mm x 270mm.
2	■ Bottom surface; delamination and dry fibres. 510mm x 180mm

The white area 21 of the c-scan 20 is where the delamination of the example 16 has occurred after the simulated lightning strike test. This shows the damaged area is large for the panel 10 of example 16 which comprises no metal coated particles.

Example 17 (Simulated Lightning Strike)

M21 resin was modified with silver coated glass spheres (2 vol.%, 5 wt.% of resin), blended using a Winkworth mixer and then filmed onto silicone release paper. This resin film was then impregnated onto unidirectional intermediate modulus carbon fibre which produced a prepreg with an areal weight of 268g/m² at 35 wt.% of resin. Two six-ply prepregs were produced (lay up 0/90) which were approximately 60cm by 60cm and were cured on a vacuum table at a pressure of 7 bar at 177°C for 2 hours. A lightning strike test was then carried out according to the method of Example 16.
Figures 4 and 5 show a damaged panel 30 after simulated lightning strike. Figure 4 shows an upper surface 31 of the panel 30, and Figure 5 shows a lower surface 32 of the panel 30. It is clearly seen that the simulated lightning strike has not penetrated the composite panel 30 of the invention.
An Ultrasonic c-scan 40 was carried out on the lightning struck panel 30 using an R/D Tech Omniscan MX from Olympus. The scan 40 is shown in Figure 6. The scan 40 shows that the white area 41 of the modified panel 30 is reduced in comparison to the unmodified Example 16 of Figures 1 and 2.

Therefore, the panel 30 with metal coated particles has a much reduced damage area when compared to the comparative example panel as shown in Figures 1 and 2.

Table 12: Test parameters of lightning strike tests for Example 17.

Figures	A Component Current, I (kA)	Action Integral, AI (10⁶ A²s)	B Component current, I (kA)	C Component Charge, Q
4	197.1	2.20	1.74	25.0
5	195.7	2.10	1.75	29.3

Table 13: Description of damaged area after lightning strike test.

Figures	Description of Damage
4	No visible damage to inner skin, split & tufted over 280 x 240mm on outer skin
5	No visible damage to inner skin, split & tufted over 280 x 220mm on outer skin

Figure 7 shows a photomicrograph 50 of a polished cross section of the panel 30 shown in Figures 4 and 5. The silver coated glass spheres 53 are clearly seen to be located in the resin interleaf 52, and are contacting the carbon plies 51.

Example 18 (Simulated Lightning Strike)

M21 resin was modified with silver coated glass spheres (2 vol.%, 5 wt.% of resin) and carbon nanofibre (150 nm diameter, 2 wt% of resin) blended using a Winkworth mixer and then filmed onto silicone release paper. This resin film was then impregnated onto unidirectional intermediate modulus carbon fibre which produced a prepreg with an areal weight of 268g/m² at 35 wt.% of resin. Two six-ply prepregs were produced (lay up 0/90) which were approximately 60cm by 60cm and were cured on a vacuum table at a pressure of 7 bar at 177°C for 2 hours. A lightning strike test was then carried out according to the method of Example 16.
Figures 8 and 9 show a damaged panel 60 after simulated lightning strike. Figure 8 shows an upper surface 61 of the panel 60, and Figure 9 shows a lower surface 62 of the panel 60. It is clearly seen that the simulated lightning strike has not penetrated the composite panel 60 of the invention.
An Ultrasonic c-scan 70 was carried out on the lightning struck panel 60 using an R/D Tech Omniscan MX from Olympus. The scan 70 is shown in Figure 10. The scan 40 shows that the white area 41 of the modified panel 60 is reduced in comparison to the unmodified panel 10 of Figures 1 and 2.

Therefore, the panel 60 with metal coated particles and carbon nanofibres has a much reduced damage area when compared to the Example 16 as shown in Figures 1 and 2.

Table 14: Test parameters of lightning strike tests for Example 18.

Figures	A Component Current, I (kA)	Action Integral, AI (10 ⁶ A²s)	B Component current, I (kA)	C Component Charge, Q
8	198.4	2.20	1.74	25.0
9	197.1	2.10	1.75	29.3

Table 15: Description of damaged area after lightning strike test.

Figures	Description of Damage
8	No visible damage to inner skin, 300mm split, tufting over 300x200mm on outer skin.
9	No visible damage to inner skin, 300mm split, tufting over 200x200mm on outer skin.

It is therefore shown that use of electrically conductive particles in a polymeric resin of a composite material provides for reduced resistivity. This reduced resistivity provides improved performance of the composite material during lightning strikes as shown in Examples 16 to 18.
It is to be understood that the invention is not to be limited to the details of the above embodiments, which are described by way of example only. Many variations are possible.

Claims

A composite material comprising;
i) at least one prepreg, said prepreg comprising at least one polymeric resin and at least one electrically conductive fibrous reinforcement; and

ii) electrically conductive particles dispersed in the polymeric resin;
wherein the polymeric resin is present as a polymeric resin layer on one side of the prepreg, and when laid onto another such prepreg, produces a polymeric resin interleaf layer comprising electrically conductive particles, wherein the conductive particles act as electrical conductance bridges across the interleaf thickness thereby connecting plies of fibrous reinforcement and improving the z-directional electrical conductance and wherein the electrically conductive particles are present at a level insufficient to impart electrical conductivity to the resin.
A composite material according to claim 1, wherein the polymeric layer has a thickness of from 1 to 100 micrometres, preferably from 1 to 50 micrometres, more preferably from 5 to 50 micrometres.
A composite material according to claim 1 or claim 2, wherein the electrically conductive particles comprise metal coated conducting particles or non-metallic conducting particles.
A composite material according to claim 3, wherein the metal coated conducting particles comprise core particles which are substantially covered by a suitable metal.
A composite material according to either of claims 3 or 4, wherein the metal coated conducting particles have an aspect ratio of <100.
A composite material according to any of claims 3 to 5, wherein at least 90 % of the metal coated conducting particles or non-metallic particles have a size in the range 0.3 µm to 100 µm, preferably from 1 µm to 50 µm, more preferably from 5 µm to 40 µm.
A composite material according to any of claim 4 to 6, wherein the core particles are selected from polymer, rubber, ceramic, glass, mineral, or refractory products.
A composite material according to claims 4 to 7, wherein the core particles are porous, hollow, or have a core-shell structure.
A composite material according to any of claims 4 to 8, wherein metals suitable for coating the core particles include silver, gold, nickel, copper, tin, aluminium, platinum, or palladium.
A composite material according to any of claims 3 to 9, wherein the electrical resistivity of the metal coating is less than 3 x 10^-5 Ωm.
A composite material according to claim 3, wherein non-metallic conducting particles are selected from graphite flakes, graphite powders, graphite particles, graphene sheets, fullerenes, carbon black, intrinsically conducting polymers (ICPs - including polypyrrole, polythiophene, polyaniline), charge transfer complexes, or any combination thereof.
A composite material to claim 1, wherein the electrically conductive particles comprise carbon particles.
A composite material according to any preceding claim, wherein the composite material comprises carbon nano materials.
A composite material according to claim 13, wherein the carbon nano materials are selected from carbon nanofibres, carbon nanotubes, or a combination thereof.
A composite material according to any preceding claim, wherein the electrically conductive particles are present in the range 0.2 vol.% to 20 vol.%, preferably 0.4 vol.% to 15 vol.% , more preferably 0.8 to 10 vol.% of the composite material.
A composite material according to any one of the preceding claims, which comprises from 5 to 45 wt% toughening particles, preferably 5 to 25 wt%, more preferably from 10 to 15 wt%.
A composite material obtainable by the process of laying up a plurality of composite material according to any one of the preceding claims, wherein the polymeric resin layer becomes an interleaf layer between adjacent fibre layers.
A cured composite material, which comprises a composite material according to any one of the preceding claims wherein the composite material is cured.
An aerospace article comprising the cured composite material of claim 18.